Flexible power tool motor pack and method of making the same

ABSTRACT

A power tool motor pack that includes common components adapted to couple to a first component customized for a first power tool application and to couple to a second component customized for a second power tool application. When the motor pack is used in the first power tool application, the common components are coupled to the first customized component. When the motor pack is used in the second power tool application, the common components are coupled to the second customized component.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a divisional application of U.S. patent applicationSer. No. 10/374,340 filed on Feb. 26, 2003.

FIELD OF THE INVENTION

The present invention relates generally to power tools and moreparticularly to power tool motor packs.

BACKGROUND OF THE INVENTION

A wide variety of power tools are known in the art, many of which areused in professional applications. In professional applications, powertools are typically subjected to heavy usage and high torques. For atleast these reasons, customized motor packs are usually speciallydesigned to satisfy the operational requirements of the professionalpower tool application in which the motor packs will be used. Indeed,developing motor packs for a new line of power tools intended forprofessional applications often involves designing and/or retooling asubstantial number of the motor pack parts and components. Hence, thetime, resources, and costs associated with development of such motorpacks can be rather extensive and perhaps somewhat prohibitive.

SUMMARY OF THE INVENTION

In accordance with the invention, power tool motor pack for use in atleast a first and second power tool application is provided. The powertool motor pack comprises a common component adapted to couple to anyone of a first fan baffle customized for the first power toolapplication and to couple to a second fan baffle customized for thesecond power tool application. The common component can include aplurality of components as can the customized component for each powertool application. In an aspect of the invention, a customized componentcan be used in more than one of the power tool applications.

Further areas of applicability of the present invention will becomeapparent from the detailed description provided hereinafter. It shouldbe understood that the detailed description and specific examples below,while indicating at least one preferred embodiment of the invention, areintended for purposes of illustration only and are not intended to limitthe scope of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention will be more fully understood from the detaileddescription and the accompanying drawings, wherein:

FIG. 1 is a perspective view of a power tool motor pack configured for apower circular saw according to the principles of the present invention;

FIG. 2 is a top view of the motor pack shown in FIG. 1;

FIG. 3 is a longitudinal cross-sectional view of the motor pack takenalong the plane 3—3 in FIG. 2;

FIG. 4 is a longitudinal cross-sectional view of the motor pack takenalong the plane 4—4 in FIG. 2;

FIG. 5 is a perspective view of a power tool motor pack configured for apower reciprocating saw according to the principles of the presentinvention; and

FIG. 6 is a perspective view of a power tool motor pack configured for apower impact wrench according to the principles of the presentinvention.

Corresponding reference characters indicate corresponding featuresthroughout the drawings.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The following description of the preferred embodiment(s) is merelyexemplary in nature and is in no way intended to limit the invention,its application, or uses.

Referring generally to FIG. 1, there is shown a power tool motor pack 10in a configuration intended for a power circular saw according to oneembodiment of the present invention. Although FIG. 1 shows the motorpack 10 configured for a power circular saw, the present invention ismore generally directed towards a motor pack that includes commoncomponents which can be used in any one of a wide variety of differentpower tool applications. The common components are adapted to couple tocomponents customized for the different power tool applications, whichin the exemplary embodiments include a power circular saw (FIGS. 1through 4), a power reciprocating saw (FIG. 5), and a power impact,wrench (FIG. 6).

By introducing the common components, the present invention eliminatesthe need for developing these common components each time a new ordifferent motor pack is being developed. In doing so, the presentinvention thus substantially reduces the amount of resources, time, andcosts needed for motor pack development. Indeed, using the presentinvention may allow motor packs to be developed for different power toolapplications with the redesigning and/or retooling of only one or twomotor pack components.

In the illustrated embodiments, the commons components of the power toolmotor packs 10 (FIG. 1), 110 (FIG. 5), 210 (FIG. 6) include an end cap12, a brush system 43 (FIG. 4), an armature 33 (FIG. 3) (other thanarmature shaft 36 and windings 40 of armature 33), a permanent magnetstator 37 and a motor can 14. The end cap 12 typically provides a rearbearing support such as boot 54 (FIG. 3). The end cap 12 and the motorcan 14 are adapted to couple to each of a first fan baffle 16, a secondfan baffle 116, and a third fan baffle 216. Each fan baffle 16, 116, 216is customized for the particular power tool application in which it willbe used, i.e., a power circular saw, a power reciprocating saw, and apower impact wrench, respectively, in the embodiments described below.It should be understood that the common components can be used in otherpower tool applications, such as drills, hammer drills, miter saws, jigsaws, and others, with the fan baffles used in each such power toolapplication customized for that application but configured to couple tothe end cap 12 and motor can 14.

The fan baffle 16, 116, 216 to which the end cap 12 and motor can 14 areultimately coupled will depend on which of the motor packs 10, 110, 210is being assembled. That is, the end cap 12 and motor can 14 are coupledto the first fan baffle 16 in the motor pack 10, are coupled to thesecond fan baffle 116 in the motor pack 110, and are coupled to thethird fan baffle 216 in the motor pack 210.

As described below, a common scheme is established for coupling thecommon components to the customized components. In an aspect of theinvention, this common scheme is to provide the common components andcustomized components with a common mounting or fastener hole pattern.It should be noted, however, that the manner in which the variouscustomized components are coupled to one another may be unique to theparticular power tool application for which the components werecustomized. In addition, each customized component need not be unique toa single power tool application.

Referring to FIGS. 1 through 4, the circular saw motor pack 10 will nowbe described in detail. As shown, the motor pack 10 includes the end cap12, the motor can 14, the fan baffle 16, and a gear case 18, which alsofunctions as a mounting plate and a front bearing support. The gear case18 is coupled to the fan baffle 16 with suitable fasteners 19, such asthreaded screws.

The end cap 12 includes two flange portions 20 (FIG. 3). Each flangeportion 20 is provided with one or more holes 22 in a patterncorresponding to bosses or holes 24 provided in the fan baffle 16.Indeed, each fan baffle 16, 116 (FIG. 4), 216 (FIG. 5) is provided withthis common fastener hole pattern. This, in turn, allows the end cap 12and motor can 14 to be coupled to any one of the fan baffles 16, 116,216 by way of suitable fasteners 26.

In the embodiment shown in FIG. 3, the fan baffle 16 is coupled to theend cap 12 and the motor can 14 as follows. The fasteners 26 extendthrough the holes 22 provided in the flange portions 20 of the end cap12, through the motor can 14, and finally into the holes 24 provided inthe fan baffle 16. Within the motor can 14, the fasteners 26 passthrough gaps or spaces defined between two semi-circular magnet members35 (FIG. 4) of a permanent magnet stator 37. (While the embodiment ofFIGS. 1–4 is illustratively a permanent magnet motor with a permanentmagnet stator, it should be understood that the instant invention canalso be utilized in other motors, such as a permanent magnet motorhaving a permanent magnet armature and a wound stator or in a universalmotor having a wound armature and stator.) The fasteners 26 also passthrough a space defined between an inner surface of the motor can 14 andthe laminations 38 and windings 40 of armature 33.

The fasteners 26 may comprise a wide range of suitable fasteners. In theillustrated embodiment, the fasteners 26 comprise threaded screws thatself-tap into the corresponding screw bosses or holes 24 in the fanbaffle 16. After being threaded into the holes 24, the screw heads 28are positioned against the flange portions 20, thereby securing the fanbaffle 16 to the end cap 12, with the motor can 14 being essentiallyclamped or sandwiched between the fan baffle 16 and the end cap 12.

Referring now primarily to FIG. 4, the motor pack 10 generates power byutilizing a wound armature 33 and a permanent magnet stator 37 havingmagnets 35. Armature 33 has an armature shaft 36 around which arepositioned laminations 38, in which windings 40 are wound, and a tubularmember or sleeve 42 surrounding armature shaft 36. A commutator 32 isaffixed on one end of armature shaft 36. Brush system 43 includes abrush 34 at least partially enclosed in a brush box 44, which iselectrically connected to a power source. Shunts 46 are used toelectrically connect the brushes 34 to their corresponding brush boxes44. The brush boxes 44 are attached to the end cap 12 in manner thatplaces the brushes 34 in contact with the commutator 32. To ensure thatgood electrical contact is maintained between the brushes 34 and thecommutator 32 even while the commutator 32 is rotating, springs 48 areused to resiliently bias the brushes 34 against the commutator 32.Generally, the commutator brushes 34 transfer power from the powersource to the commutator 32 of armature 33 causing the armature 33 tospin. To allow the armature shaft 36 to rotate relatively freely,bearings 50 and 52 are disposed at opposite end portions of the armatureshaft 36. The bearing 50 is shown positioned within a boot 54.

The motor pack 10 also includes an axial flow fan 30 that produces anaxial airflow (i.e., an airflow parallel with a central longitudinalaxis 31 of the motor pack 10). However, the present invention allows adeveloper to customize the fan and/or fan baffle according to theairflow properties preferable for the intended power tool application.For example, the motor packs 110 (FIG. 5) and 210 (FIG. 6) each includea radial flow 130, 230, respectively, that produces a radial airflow(i.e., an airflow tangentially to the central longitudinal axis of themotor pack).

In addition to the fans 30, 130, 230 and baffles 16, 116, 216, thepresent invention also allows other motor pack components to becustomized as well. Other exemplary motor pack components which may becustomized include fan baffles 16, 116, 216, fans 30, 130, 230, armatureshafts 36, 136, 236, gear cases 18, 118, 218, front bearing supports,mounting plates, windings 40, and bearing 52, depending at least in parton the particular requirements of the power tool application intendedfor the motor pack.

In the illustrated embodiments, the components common to each of themotor packs 10, 110, and 210 include the end cap 12, armature 33 (otherthan armature shaft 36) including but not limited to commutator 32 andlaminations 38, brush system 43 (e.g., brushes 34, brush boxes 44,shunts 46, springs 48), permanent magnet stator 37 and the motor can 14.In addition to the end cap 12 and the motor can 14, the motor packs 10,110, 210 may also include other common components.

It should be understood that depending on the applications, certain ofthe customized components can be made common and vice-versa. Forexample, the armature shaft 36 and windings 40 may be common for certainapplications instead of custom.

In another preferred form, the present invention provides a method ofmaking motor packs for different power tool applications. The methodgenerally comprises providing at least one common component adapted tocouple to a first customized component for a first power toolapplication and to couple to a second customized component for a secondpower tool application; coupling the common component to the firstcustomized component when the power tool motor pack is intended for thefirst power tool application; and coupling the common component to thesecond customized component when the power tool motor pack is intendedfor the second power tool application.

In the exemplary embodiments shown and described herein, the methodcomprises establishing a common scheme for coupling the end cap 12 andthe motor can 14 to couple to each of the first, second, and third fanbaffles 16, 116, 216; coupling the end cap 12 and motor can 14 to thefirst fan baffle 16 when the intended power tool application for themotor pack 10 is a power circular saw; coupling the end cap 12 and motorcan 14 to the second fan baffle 116 when the intended power toolapplication for the motor pack 110 is a power reciprocating saw; andcoupling the end cap 12 and motor can 14 to the third fan baffle 216when the intended power tool application for the motor pack 210 is apower impact wrench.

In each of the motor pack configurations 10, 110, 210, a common scheme(e.g., fasteners 26 and a common fastener hole pattern) is used tocouple the end cap 12 and motor can 14 to the corresponding fan baffle16, 116, 216. In addition, the method may further include coupling thefan baffle 16, 116, 216 to other customized components (e.g., gear cases18, 118, 218, fans 30, 130, 230, mounting plates, front bearingsupports, armature shafts 36, 136, 236, etc.). Moreover, the method mayalso include coupling the end cap 12 and the motor can 14 to othercommon components (e.g., commutator 32 and laminations 38 of armature33, brushes 34, brush boxes 44, shunts 46, springs 48, permanent magnetstator 37, and bearing 50).

Because of their substantial similarity in construction, the motor packs10, 110, 210 can be produced on the same production line with minortooling changes, as needed, for the customized components. This, inturn, allows for substantial reductions in manufacturing costs.

It is anticipated that the invention will be applicable to a wide rangeof power tool applications. Accordingly, the specific references topower circular saw, power reciprocating saw, and power impact wrenchshould not be construed as limiting the scope of the present inventionto these specific power tool applications.

The description of the invention is merely exemplary in nature and is inno way intended to limit the invention, its application, or uses. Thus,variations that do not depart from the substance of the invention areintended to be within the scope of the invention. Such variations arenot to be regarded as a departure from the spirit and scope of theinvention.

1. A method of making power tool motor packs for different power tool applications, the method comprising: providing at least an end cap and motor can; selecting a fan baffle from at least first and second baffles that each have a coupling portion that couples with at least one of the end cap and motor can, the first fan baffle having a portion customized for a first power tool application and the second fan baffle having a portion customized for a second power tool application, the customized portion of the first fan baffle being different than the customized portion of the second fan baffle; coupling the at least one of the end cap and motor can to the first fan baffle when the power tool motor pack is intended for the first power tool application; and coupling the at least one of the end cap and motor can to the second fan baffle when the power tool motor pack is intended for the second power tool application.
 2. The method of claim 1, wherein the coupling portion of the first and second fan baffles includes a flange having a fastener hole pattern that matches a fastener hole pattern in at the at least one of the end cap and motor can and using fasteners to couple the end cap and motor can to the first fan baffle when the power tool motor pack is made for the first power tool application and using the fasteners to couple the end cap and motor can to the second fan baffle when the power tool motor pack is made for the second power tool application.
 3. The method of claim 2 wherein the fasteners include-threaded screws.
 4. The method of claim 2, further including: coupling first other customized components to the customized portion of the first fan baffle when the power tool motor pack is intended for the first power tool application; and coupling second other customized components to the customized portion of the second fan baffle when the power tool motor pack is intended for the second power tool application.
 5. The method of claim 4 wherein coupling first other customized components to the customized portion of the first fan baffle includes coupling a first gear case customized for the first power tool application and coupling second other customized components to the customized portion of the second fan baffle includes coupling a second gear case customized for the second power tool application.
 6. The method of claim 4, further including coupling a brush assembly to at least one of the end cap and the motor housing.
 7. The method of claim 6, further including disposing a commutator on a first armature shaft customized for the first tool application when the power tool motor pack is intended for the first power tool application, disposing the commutator on a second armature shaft customized for the second tool application when the power tool motor pack is intended for the second power tool application, and disposing the commutator and armature shaft in the end cap and motor housing.
 8. A method of making power tool motor packs for at least a power circular saw, a power reciprocating saw and a power impact wrench, the method comprising: coupling an end cap and a motor can to a circular saw fan baffle when making the power tool motor pack for the circular saw, the circular saw fan baffle having a flange with a fastener hole pattern that mates with a fastener hole pattern in at least one of the end cap and motor can; coupling the end cap and motor can to a reciprocating saw fan baffle when making the power tool motor pack for the reciprocating saw, the reciprocating saw fan baffle having a flange with a fastener hole pattern that mates with the fastener hole pattern in at least one of the end cap and motor can; coupling the end cap and the motor can to a power impact wrench fan baffle when making the power tool motor pack for the power impact wrench, the power impact wrench fan baffle having a flange with a fastener hole pattern that mates with the fastener hole pattern in at least of the end cap and motor can; each of the circular saw fan baffle, reciprocating saw fan baffle and power impact wrench fan baffle having a customized portion that differs from the customized portion of the customized portions of the other fan baffles.
 9. The method of claim 8 including coupling a gear case customized for the circular saw to the circular saw fan baffle when making the power tool motor pack for a circular saw, coupling a gear case customized for the reciprocating saw to the reciprocating saw fan baffle when making the power tool motor pack for the reciprocating saw, and coupling a gear case customized for the power impact wrench to the power impact wrench fan baffle when making the power tool motor pack for the power impact wrench. 